Rajan Wilcox
If your fuel oil tank gauge is defective, you may want to consider replacing it. This can be done by yourself if you are handy, or you can contact a professional such as your oil or HVAC company, a burner technician, or a licensed plumber. The tools required for this task include rubber gloves, a pipe wrench, pipe dope or thread sealant, and penetrating oil. The process involves understanding how your float gauge works, loosening the fitting, pulling up the disc, and then removing and replacing the float assembly. You can purchase replacement gauges and necessary tools from hardware stores, plumbing supply companies, or online retailers. It is important to regularly monitor your oil level to avoid running out of heating fuel or overfilling your tank, which can be hazardous and costly.
| Characteristics | Values |
|---|---|
| Tools required | Rubber gloves, 14" pipe wrench (or bigger), pipe dope/thread sealant, penetrating oil |
| Float gauge composition | Floating piece ('float'), hinged arm, plastic disc, plastic vial |
| Common issues with float gauges | Float gets stuck, weighed down by sludge, bent metal in arm, assembly rotates inside tank |
| Alternative to float gauge | Smart Oil Gauge (uses ultrasonic sensor) |
| Steps to replace float gauge | 1. Loosen fitting, 2. Pull disc up and loosen fitting completely, 3. Remove float assembly, 4. Install new float gauge |
| Average residential heating oil tank capacity | 275 gallons |
| Gauge measurement | Measures percentage of tank that is full or available, not number of gallons remaining |
| Gauge accuracy | Not always accurate due to malfunction, oil buildup, tank shape, air and extra tank space |
| Manual tank gauging tools | Gauge stick (wooden yardstick or metal rod) |
| Manual tank gauging steps | 1. Remove top fill valve cap, 2. Lower stick until it touches tank bottom, 3. Bring stick up and read depth of oil, 4. Record measurement, 5. Wipe stick clean, 6. Repeat measurement, 7. Secure valve cap |
| Gauge replacement cost | $12-$25 |
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What You'll Learn
Understanding how a float gauge works
A float gauge is a device that measures the level of oil in a tank. It is similar to the fuel gauge in a car in that it measures the level of fuel remaining but not the number of gallons inside. Float gauges are standard in most fuel oil tanks and feature an arm with a float attached to one end and a hinge on the other. The float sits on top of the oil and moves down as the oil level lowers. The hinge is connected to a disc inside a plastic vial or cylinder, which you can see from the outside, that moves up and down with the float. This disc has markings to indicate the level of oil in the tank: Full, 3/4, 1/2, and 1/4.
The float gauge is not a precise tool; it is meant to give you a rough idea of how much oil is in your tank. The tick marks on the plastic vial are not precise enough to distinguish between the top and bottom of the disc, so you should look for where the middle of the disc lines up with the markings. Additionally, the float gauge becomes less accurate when the oil level is low because the bottom of the tank is rounded. As a rule of thumb, order more oil when the gauge reads 1/4 full. This will give you a few days' buffer before you completely run out.
Over time, the float gauge can become stuck or weighed down by sludge, causing it to read improperly. The thin metal piece connecting the hinge to the disc can also bend, or the whole assembly can rotate inside the tank, causing the float to get wedged against the inner wall. If you suspect your float gauge is stuck, you can test it by removing the plastic vial and pressing the disc with your finger. If the gauge is working properly, the disc should move down and then slowly float back up.
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Tools required for replacement
To replace a fuel oil tank gauge, you will need the following tools:
- Rubber gloves (remember to wear old clothes too, as heating oil has a strong odour)
- A wrench that is 14″ or bigger
- Pipe dope or thread sealant
- Penetrating oil/liquid wrench (optional)
If you are uncomfortable with any of these tools or unsure about the process, it is best to contact a professional for help.
Now, let's go over the tools required in more detail:
Rubber gloves are important for protecting your hands from the oil and its strong odour. It is also recommended to wear old clothes, as the oil can stain or leave a lingering smell on your clothing. The wrench you choose should be 14″ or bigger to effectively loosen and tighten the necessary fittings. Pipe dope, or thread sealant, is crucial for creating a tight seal and preventing leaks around the fittings. Finally, penetrating oil or liquid wrench (optional) can be used to soak any stubborn fittings that are difficult to loosen.
In addition to these tools, it is important to have a basic understanding of how a float gauge works. A float gauge consists of a floating piece (the 'float'), which can be made of cork or plastic, that sits on top of the oil. This float is attached to a hinged arm, which moves up and down as the oil level changes. At the other end of the arm is a plastic disc that sits inside a plastic vial. The disc moves up and down with the float, providing a rough indication of the oil level in the tank.
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Step-by-step guide to replacing a gauge
Step 1: Understand your float gauge
Before you begin, it is important to understand how a float gauge works. This will aid in removing it so you know what to expect. Essentially, there is a floating piece (the 'float') that sits atop the oil. This float is usually made of cork or plastic and is attached to a hinged arm. At the other end of this arm is a plastic disc that moves up and down with the float. The disc is housed behind a plastic vial that can be removed by hand. Together, the disc and vial provide a rough indication of the oil level in the fuel oil tank.
Step 2: Loosen the fitting
First, remove the plastic vial by hand to expose the disc. Then, position a 14-inch pipe wrench (or bigger) on the metal fitting that threads into the tank. Use both hands to loosen the fitting, but only slightly—by no more than half a turn. This is because if you loosen it too much, the float will hit the inside wall of the tank. If you are having trouble loosening the fitting, you can try soaking it in a penetrating oil such as Liquid Wrench for several hours or a couple of days.
Step 3: Pull the disc up and loosen the fitting completely
Now that the fitting is loose, you will need to use both hands to pull the disc up as far as it will go. This will lift the float out of the oil and allow you to rotate the assembly. By lifting the float out, the assembly can rotate without crashing into the inside of the tank. Once the disc is up, you can continue unscrewing the float gauge fitting from the tank.
Step 4: Remove the float assembly
Once the fitting is completely loose, you can remove the float assembly. Have paper towels and a garbage bag ready to catch any dripping oil, and place the assembly in the garbage bag immediately.
Step 5: Install your new float gauge
To install a new float gauge, simply reverse the previous steps. Begin by cleaning the fitting on the tank and applying pipe dope to the threads of the new float gauge assembly. Use a marker on the fitting to indicate the direction that the arm should fall once the assembly is on the tank. This will ensure that the float can extend into the open area of the tank and will not hit the inner wall. Gently lower the float into the tank until the fitting mates with the tank. Gently lift the disc to raise the float out of the oil, and hand-tighten the assembly as far as you can. Keep lifting the disc and tighten with a pipe wrench until it is snug. Make sure to stop tightening when the arm is oriented properly in the tank. Once tight, hand-tighten the plastic vial in place.
Alternative Options
If you are unhappy with your float gauge, there are alternative options available, such as the Smart Oil Gauge, which uses an ultrasonic sensor to detect the level of oil in the tank. This type of gauge never comes into direct contact with the heating oil, avoiding any sludge buildup.
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Alternative options to float gauges
If you're unhappy with your heating oil float gauge or are tired of replacing it, there are some alternative options available.
One option is to install a Smart Oil Gauge, which uses an ultrasonic sensor to detect the oil level in the tank. This type of gauge is threaded into an extra opening on your tank and can be used in addition to a traditional float gauge. It is much easier to install, as it simply needs to be tightened with a pipe wrench after applying pipe dope to the threads. The Smart Oil Gauge can be connected to WiFi through an app on your phone, allowing you to monitor your usage remotely. It also provides more accurate readings, especially when the tank is low, and can send text and email alerts when the tank is low.
Another alternative to the traditional float gauge is a yardstick or "dipstick." This method involves manually measuring the contents of the tank by lowering a stick (preferably varnished) gently until it touches the bottom of the tank and then reading the depth of the oil. This process should be repeated weekly and the data analyzed to understand the oil usage and detect any potential leaks.
Additionally, there are other types of fuel tank float gauges available, such as clock gauges or cat and mouse gauges, which provide a simple and cost-effective method of visually identifying the level of fuel in the tank. These gauges are typically fitted on the top of a storage tank and can be easily installed by the homeowner without expert fitting.
Finally, there are remote reading products and direct-reading products available on the market, which can provide real-time data on fuel levels and help with monitoring and detecting potential issues.
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How to check oil levels manually
Locating your oil tank
Locate your oil tank. Home oil tanks are often found aboveground, in a basement, on an exterior side of the house, or underground, buried on the property. They are quite large, so a quick pass around your home should do the trick.
Reading the Oil Tank Float Gauge
Once you've found your oil tank, you can check the oil levels by reading the gauge. Most oil tanks come with a gauge installed, so you don't need to worry about finding a way to measure the oil level. Oil gauges are clear, cylindrical vials with a float inside. They are typically located on the top of the tank to make reading the gauge easy. Most gauges have standard markings to indicate the levels. The float in the vial will be positioned around one of the markings to show the level of fuel in the tank.
Calculating the Gallons in Your Tank
While reading the gauge indicates the fuel level in your tank, it doesn't tell you how many gallons you have left. You can estimate how many gallons you have left in the tank with a simple calculation. Knowing the size of your tank and how many gallons it holds at total capacity will help you figure out the number of remaining gallons. For instance, if you have a typical 275-gallon tank, the average fuel capacity is 240 gallons. If the float gauge indicates you have 1/4 of a tank of fuel, divide 240 by 0.25 to calculate that you have around 60 gallons left.
Manually checking your oil level
If you have a broken oil tank gauge or have never had one, you can still check your oil tank level. You can use a stick, like a meter stick or metal rod, to check the oil level manually. The next time your tank is full, dip the stick into the tank and mark off the top of the oil level. When you check the oil level later, put the stick in again and see if the new oil level falls below the mark.
Using a gauge stick
Another way to manually check your oil level is to use a gauge stick, also known as a "tank stick" or "dipstick". While many people use a wooden yardstick or metal rod, the best gauge sticks are varnished to get the most accurate reading possible. A varnished stick limits the spread of the oil on the stick and provides the measurement. Be sure the stick you choose is straight and not warped or bent.
Follow these steps to manually measure the contents of your oil tank with a gauge stick:
- Turn the top fill valve cap counter-clockwise and remove the cap from the tank.
- Lower the stick gently until it touches the bottom of the tank.
- Bring the stick back up and read the depth of the oil to the nearest eighth of an inch.
- Record the measurement in your manual tank gauging record.
- Wipe the measuring stick clean with a dry cloth.
- Lower the tank stick and measure a second time. Record these results.
- Secure the top fill valve cap to prevent leaking.
- Repeat the manual tank gauging process each week.
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